Ground mounted solar module integration system

ABSTRACT

Embodiments of the present inventions are directed to systems, devices for use with systems, and method of mounting and retaining solar panels. A solar module mounting system may include: a support mechanism including a support post pivotably attached to a support base, and an attachment module for attaching a solar panel to the support mechanism.

CROSS REFERENCE TO RELATED APPLICATIONS

The current application is a continuation of and claims priority to andthe benefit of U.S. Non-Provisional Patent application Ser. No.12/846,259 filed Jul. 29, 2010, the entire contents of which areincorporated herein by reference.

BACKGROUND

Embodiments disclosed herein are directed to systems, devices for usewith systems, and methods of mounting and retaining solar panels.

Solar (e.g., photovoltaic) panels are often manufactured in the form offlat rigid structures. To facilitate the performance of the function ofgenerating electricity, solar panels may be mounted in an area exposedto the sun or other source of light. Often, it is desirable to mountsolar panels outdoors at an angle from the horizontal so that they willmore directly face the sun during peak daylight hours as opposed topanels mounted flat on the ground. In some applications, it may bedesirable to mount a number of solar panels together in an array inorder to combine the power generation capabilities of the individualpanels. In many instances, it may be desirable that mounting systems forsolar panel arrays retain the solar panels in place. This may beaccomplished by attaching the solar panels to one another in a mountingsystem and/or by mounting the panels to the mounting system.

For example, U.S. Patent Application Publication No. 2007/0133474 toMascolo et al. describes a supported solar panel assembly including asolar panel module comprising a solar panel and solar panel modulesupports including module supports having support surfaces supportingthe module, a module registration member engaging the solar panel moduleto position the solar panel module on the module support, and a mountingelement. U.S. Pat. No. 6,534,703 to Dinwoodie describes a solar panelassembly for use on a support surface comprising a base, a solar panelmodule, a multi-position module support assembly, and a deflector.

SUMMARY

Devices, systems, and techniques are disclosed for mounting andretaining solar panels. In some embodiments, solar panels are mounted inarrays on the ground, e.g. in an open field. In some embodiments, theground includes local surface undulations, and the array of solar panelsmay be constructed to compensate for these undulations.

In one aspect, a method is disclosed for installing a solar panel array,the method including acts of: providing a support mechanism including asupport post pivotably attached to a support base; selecting an angularorientation of the support post with respect to the support base;setting the selecting an angular orientation of the support post;providing a solar panel; selecting a height on the support mechanism forattaching the panel; and attaching the panel at the selected height.

In another aspect, an apparatus for mounting solar panels is disclosedincluding: a support mechanism including a support post pivotablyattached to a support base and an attachment module for attaching thesolar panel to the support mechanism.

In one aspect, a method is disclosed of installing a solar panel array,the method including the steps of: obtaining a first support mechanismincluding a support post pivotably attached to a support base; selectingan angular orientation of the support post with respect to the supportbase; setting the selected an angular orientation of the support post;obtaining a first solar panel; selecting a height on the first supportmechanism for attaching the first panel; and attaching the first panelto the first support mechanism at the selected height.

In some embodiments, the angular orientation of the support post isselected to compensate for a local undulation in a surface on which thefirst support mechanism is located.

In some embodiments, the height on the first support mechanism forattaching the panel is selected to compensate for the local undulationin the surface on which the first support mechanism is located.

In some embodiments, attaching the first panel to the first supportmechanism includes coupling an attachment module to the first solarpanel; and after coupling the attachment module to the first solarpanel, coupling the attachment module to the first support mechanism.

In some embodiments, the first support mechanism includes a supportframe coupled to the support post. The support frame includes: a firstelongated member coupled to the support post and extending from a frontend to a rear end along a direction substantially perpendicular to thesupport post; a second elongated member extending at an angle to thefirst elongated member between a front end coupled to the front end ofthe first elongated member and a rear end, the second elongated memberinclude at least one facility adapted to receive the attachment moduleto couple the solar panel to the support frame; and a facility foradjusting the height of the first elongated member relative to thesupport base to a selected one of a plurality of heights. The methodfurther including the steps of: selecting a height of the firstelongated member relative to the support base; setting the height of thefirst elongated member relative to the support base to the selectedheight; and coupling the attachment module to the second elongatedmember.

In some embodiments, the support frame includes a facility for adjustingthe angle of the second elongated member to the first elongated memberto a selected one of a plurality of angles. In some embodiments, themethod includes: selecting a mounting angle of the solar panel; settingthe angle of the second elongated member to the first elongated memberto correspond to the mounting angle of the solar panel;

Some embodiments include: obtaining a second solar panel; attaching thesecond solar panel to the first support mechanism by coupling anattachment module to the second solar panel; and, after coupling theattachment module to the second solar panel, coupling the attachmentmodule to the first support mechanism.

Some embodiments include: obtaining a second support mechanism, thesecond support mechanism including: a support post pivotably attached toa support base; and a support frame coupled to the support post. Thesupport frame includes a first elongated member coupled the support postand extending from a front end to a rear end along a directionsubstantially perpendicular to the support post; and a second elongatedmember extending at an angle to the first elongated member between afront end coupled to the front end of the first elongated member and arear end, the second elongated member include at least one facilityadapted to receive a second attachment module to couple the solar panelto the support frame. In some embodiments, the method includes, for thesecond support mechanism: selecting an angular orientation of thesupport post with respect to the support base and selecting a height onthe first support mechanism for attaching the first panel, where atleast one of the angular orientation of the support post and the heighton the first support mechanism for attaching the first panel is selectedto compensate for a local undulation in a surface on which the secondsupport mechanism is located; setting the selected angular orientationof the support post; and attaching the first panel to the second supportmechanism at the selected height.

Some embodiments include: obtaining a second support mechanism, thesecond support mechanism including: a support post pivotably attached toa support base; and a support frame coupled to the support post, thesupport frame including: a first elongated member coupled to the supportpost and extending from a front end to a rear end along a directionsubstantially perpendicular to the support post; and a second elongatedmember extending at an angle to the first elongated member between afront end coupled to the front end of the first elongated member and arear end, the second elongated member include at least one facilityadapted to receive a second attachment module to couple the solar panelto the support frame. In some embodiments, the method includes attachingthe front end of the first elongated member of the first supportmechanism to the rear end of the first elongated member of the secondsupport mechanism.

In some embodiments, the front end of the first elongated member of thefirst support mechanism and the rear end of the first elongated memberof the second support mechanism are attached using a facility whichallows for the relative position and angular orientation of theelongated members to be adjusted. Some embodiments include selecting andsetting the relative position and angular orientation of the attachedelongated members.

In some embodiments, the relative position or angular orientation of theattached elongated members is adjusted to compensate for a variation inchange in a slope of the surface underlying the first and second supportmechanisms.

In another aspect, a method is disclosed of installing a solar panelarray, the method including the steps of: obtaining a first plurality ofsolar panels; placing a first plurality of support mechanisms, eachincluding a support post pivotably attached to a support base, on afirst region of a surface, the first region having a generally flatportion and localized undulations.

In some embodiments, the method includes, for each respective supportmechanism in the first plurality: Selecting an angular orientation ofthe support post with respect to the support base; setting the selectedan angular orientation of the support post; selecting an attachmentheight on the first support mechanism for attaching the first panel; andattaching at least one respective solar panel to the respective supportmechanism at the selected height. In some embodiments, the selectedangular orientations and the attachment heights are selected tocompensate for the local undulations in the first region such that eachof the first plurality of panels are positioned with substantially thesame orientation relative to the generally flat portion of the surfacein the first region.

In some embodiments, the orientation relative to the generally flatportion of the surface in the first region includes a height of therespective panel relative to the generally flat portion of the surfacein the first region.

In some embodiments, the panels in the first plurality of panels areeach attached to a respective support mechanism while the supportmechanism is unattached to any other support mechanisms.

Some embodiments include attaching each support mechanism in the firstplurality of support mechanisms to at least one other support mechanismin the first plurality of support mechanisms.

Some embodiments include attaching cross bracing between at least twoadjacent support mechanisms in the first plurality of supportmechanisms.

In some embodiments, the support mechanisms in the first plurality aresubstantially identical.

Some embodiments include: obtaining a second plurality of solar panels;placing a second plurality of support mechanisms, each including asupport post pivotably attached to a support base, on a second region ofthe surface, the first region having a generally flat portion andlocalized undulations, the second region being adjacent to the firstregion and having a general slope which differs from a general slope ofthe first region. Some embodiments include, for each respective supportmechanism in the second plurality: selecting an angular orientation ofthe support post with respect to the support base; setting the selectingan angular orientation of the support post; selecting an attachmentheight on the first support mechanism for attaching the first panel; andattaching at least one respective solar panel from the second pluralityof solar panels to the respective support mechanism at the selectedheight, where the angular orientations and the attachment heights areselected to compensate for the local undulations in the second regionsuch that each of the second plurality of panels a are positioned withsubstantially the same orientation relative to the generally flatportion of the surface in the second region.

Some embodiments include attaching at least one of the supportmechanisms of the first plurality with at least one support mechanismsin the second plurality.

In some embodiments, for each support mechanisms of the first pluralitywhich is attached to a support mechanism in the second plurality: thesupport mechanism includes an attachment facility allows for therelative angular orientation of the support members to be adjusted toone of a plurality of orientations. In some embodiments, the methodincludes attaching the support mechanism includes using the facility toset the relative angular orientation to compensate for the difference inthe slopes of the first and second regions.

In some embodiments, the support mechanisms of the first and secondpluralities of support mechanisms are substantially identical.

In some embodiments, substantially no portion of each of the supportmechanisms in the first plurality is located below the surface.

Some embodiments include driving one or more nails through the at leastone of the support mechanisms and the surface to secure the supportmechanism to the surface.

In another aspect, a solar panel module mounting system component isdisclosed including: support base; a support post; a pivot pivotablycoupling the support post to the support base; and a support framecoupled to the support post and including a facility for attaching asolar panel module.

Some embodiments include one or more attachment modules adapted tocouple to the solar panel module and to couple to the solar panel moduleat a selected height and orientation relative to the support base.

In some embodiments, the support frame includes: a first elongatedmember coupled at a substantially right angle to the support post andextending from a front end to a rear end; a second elongated memberextending at an angle to the first elongated member from a front endcoupled to the front end of the horizontal member and a rear end, andincluding the facility for attaching a solar panel module; and afacility for adjusting the height of the first elongated member relativeto the support base to a selected one of a plurality of heights.

Some embodiments include a facility for adjusting the angle of thesecond elongated member to the first elongated member to a selected oneof a plurality of angles.

In some embodiments, the pivot is configured to allow the support postto pivot about at least two transverse axes. In some embodiments, thepivot is configured to allow the support post to pivot over at rangeangles from about 0 to at least about 5 degrees from normal to thesupport base. In some embodiments, the pivot is configured to allow thesupport post to pivot over at range angles from 0 to at least 10 degreesfrom normal to the support base. In some embodiments, the pivot isconfigured to allow the support post to pivot over at range angles from0 to at least 30 degrees from normal to the support base.

In some embodiments, the support base includes a base pan for receivingand bearing the weight of a ballast, the base pan configured andarranged to receive the ballast in a position such that the ballast doesnot interfere with a pivoting motion of the support post.

In some embodiments, the front end of the first elongated memberincludes a facility for attachment to an adjacent solar panel modulemounting system component.

In some embodiments, the facility for attachment of the first elongatedmember to an adjacent second solar panel module mounting systemcomponent is configured to allow adjustment of at least one of theattachment angle and the spacing between the component and the adjacentsecond solar panel module mounting system component.

Some embodiments consist or consist essentially of the support base; thesupport post; the pivot; the support frame, the one or more attachmentmodules, and attachment hardware.

Some embodiments consist or consist essentially of the support base; thesupport post; the pivot; the support frame, the one or more attachmentmodules, one or more cross bracing members adapted to extend from thecomponent to an adjacent support component, and attachment hardware. Insome embodiments, the attachment hardware consists essentially of nuts,bolts, and screws.

In some embodiments, the support base, pivot, and support post includesa first integral unit; the support frame includes a second integralunit; and the attachment module includes a third integral unit.

In some embodiments, the support base, pivot, and support post and thesupport frame include a first integral unit; and the attachment moduleincludes a third integral unit.

In some embodiments, when the component deployed on a surface (e.g., theground), substantially no portion of the component extends through thesurface.

In another aspect, a solar panel module mounting system is disclosedincluding: a first plurality of support mechanisms configured to receivea first plurality of solar panel modules, positioned on a first regionof a surface (e.g., the ground), the first region having a generallyflat portion and localized undulations, and each support mechanismincluding: a support base; a support post; a pivot pivotably couplingthe support post to the support base allowing the support post to pivotto selected one of a plurality of angular orientations relative to thesupport base; and a support frame coupled to the support post at aselected one of a plurality of attachment heights relative to thesupport base, and including a facility for attaching a solar panelmodule. In some embodiments, for each of the plurality of supportmechanisms, the respective selected angular orientation and attachmentheight compensates for the localized undulations such that each of thefirst plurality of solar panel modules is positioned with asubstantially uniform height above the generally flat portion of thefirst region.

In some embodiments, each support mechanism is directly coupled to atleast one other support mechanism.

In some embodiments, each solar panel module extends between and issupported by a pair of support mechanisms.

In some embodiments, the support mechanisms are substantially identical.

In some embodiments, each support mechanism includes a fixtureconfigured to allow coupling between the support mechanism and anothersupport mechanism and adapted to allow coupling at a selected one of aplurality of relative positions of the coupled mechanisms.

Some embodiments include a second plurality of support mechanismsconfigured to receive a second plurality of solar panel modules,positioned on a second region of a surface, the second region having agenerally flat portion with a slope differing from a slope of thegenerally flat portion of the first region and localized undulations. Insome embodiments, each support mechanism of the second pluralityincludes: a support base; a support post; a pivot pivotably coupling thesupport post to the support base allowing the support post to pivot toselected one of a plurality of angular orientations relative to thesupport base; and a support frame coupled to the support post at aselected one of a plurality of attachment heights relative to thesupport base, and including a facility for attaching a solar panelmodule. In some embodiments, for each of the second plurality of supportmechanisms, the respective selected angular orientation and heightcompensates for the localized undulations such that each of the secondplurality of solar panel modules is positioned with a substantiallyuniform height above the generally flat portion of the second region.

In some embodiments, for each support mechanisms of the first pluralitywhich is attached to a support mechanism in the second plurality: thesupport mechanism includes an attachment facility allowing for therelative angular orientation of the support members to be adjusted toone of a plurality of orientations. In some embodiments, the methodincludes attaching the support mechanisms includes using the facility toset the relative angular orientation to compensate for the difference inthe slopes of the first and second regions.

In some embodiments, the support mechanisms of the first and secondpluralities of support mechanisms are substantially identical.

In some embodiments, substantially no portion of each support mechanismsof the first and second pluralities is located below the surface.

Some embodiments include one or more nails extending through the atleast one of the support mechanisms and the surface to secure thesupport mechanism to the surface.

Various embodiments may feature any of the steps, features, and elementsdescribed above, alone, or in any suitable combination.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings are not intended to be drawn to scale. In thedrawings, each identical or nearly identical component that isillustrated in various figures is represented by a like numeral. Forpurposes of clarity, not every component may be labeled in everydrawing. In the drawings:

FIG. 1 is an array of solar panel modules;

FIG. 2A is a perspective view of a support base;

FIG. 2B is a perspective view of a support base with ballast;

FIG. 3 is a perspective view of a support frame;

FIG. 4A is perspective view of a support frame mounted on a supportbase;

FIG. 4B is a side view of the support frame mounted on a support base ofFIG. 4A;

FIG. 5 is an attachment module of a solar module mounting system;

FIG. 6A is a perspective view of the top side of a solar panel moduleillustrating attachment modules mounted on the solar panel module;

FIG. 6B is a view from the rear underside of a solar panel moduleillustrating attachment modules mounted on the solar panel module;

FIG. 6C is a view from underneath a solar panel module illustratingattachment modules mounted on the solar panel module according to anaspect of the present inventions;

FIG. 7 is a perspective view of a solar panel module mounted to asupport frame and support base;

FIG. 8 is a rear perspective view of an array of solar panel modulesfeaturing cross bracing;

FIG. 8A is a rear perspective view of an array of solar panel modulesfeaturing cross bracing;

FIG. 9 is a rear perspective view of an array of solar panel modulesdeployed on undulating ground;

FIG. 9A is a side perspective view of an array of solar panel modulesdeployed on undulating ground having regions with differing slope;

FIGS. 10A-10D are perspective views of attachment modules of a solarpanel module mounting system;

FIG. 11 is a flowchart of a method of forming an array of solar panelmodules;

FIG. 12A is a perspective view of an attachment module of a solar modulemounting system;

FIG. 12B is a perspective view of an attachment module of a solar modulemounting system attached to a solar panel module.

DETAILED DESCRIPTION

The embodiments described herein are not limited to the details ofconstruction and the arrangement of components set forth in thefollowing description or illustrated in the drawings. The embodimentsare capable of other embodiments and of being practiced or of beingcarried out in various ways. Also, the phraseology and terminology usedherein is for the purpose of description and should not be regarded aslimiting. The use of “including,” “comprising,” or “having,”“containing,” “involving,” and variations thereof herein, is meant toencompass the items listed thereafter and equivalents thereof as well asadditional items. The description of one aspect of the embodimentsdisclosed herein is not intended to be limiting with respect to otheraspects of the present embodiments.

FIG. 1 illustrates an example of a section of an array of solar panelmodules 100 that may be deployed on a mounting surface, for example, anarea of open ground such as a field. Aspects of the present embodimentsmay be applied to other mounting surfaces, such as roof structures.

The array 100 in this example includes a plurality of solar panelmodules 110. In some embodiments, solar panel module 110 is a packagedinterconnected assembly of solar cells, e.g., photovoltaic cells. Insome embodiments, the solar panel module may be used as a component in alarger photovoltaic system to offer electricity for commercial andresidential applications.

The solar panel modules 110 are illustrated in FIG. 1 as being mountedat an angle from the horizontal, but in some embodiments, the solarpanel modules may be mounted at angles other than that illustrated inFIG. 1 or even horizontally. The solar panel modules 110 may in someembodiments be mounted at different angles throughout the array 100 anduniformly in others such as the one shown in FIG. 1. The solar panelmodules 110 are shown in FIG. 1 facing away from what will be describedherein as the Top side of array 100. What is described as the Top sidemay correspond to geographical North position of the array. As shownhere, the Top side may be positioned approximately to the North so thatthe tilted faces of the panel modules are directed generally toward theSouth, e.g., tilted to more squarely face the direction of the sun foran installation north of the equator. In some embodiments, deflectorelements (not shown) may be mounted facing the lateral sides (i.e., thesides perpendicular to the Top side) at the edges of the array, or inother positions on the array to deflect wind currents.

Solar panel modules 110 in this example are mounted on support frames120 which are in turn mounted on support bases 130 (sometimes referredto, collectively, as a support mechanism). A support frame is a supportstructure that may be used to support at least a portion of a solarpanel; in this example, each support frame 120 is used to support a sideof a solar panel module 110. A support base is a support structure whichcontacts the ground and supports one or more support frames 120.Examples of support frame 120 and support base 130 are described morefully below.

Note that although a 2×2 array is shown, arrays featuring any othernumber of solar panel modules 100 arranged in any number of rows andcolumns may be used. In some embodiments the array is formed with manypanels over a large area e.g. and acre, several acres, or more.

Note also that while support frame 120 and support base 130 are shown asseparate components, but, in some embodiments, they may be integrated ina single unit.

FIG. 2A is a perspective view of a support base 130. The support baseincludes a support post 131 connected to a base pan 132. As shown,support post 131 is connected to base pan 132 with a pivot 133. Thepivot 133 allows the angle of the support post 131 relative to base pan132 to be adjusted. Pivot 133 includes two pivot bolts 134 a and 134 b,allowing post 131 to pivot in two transverse directions. Accordingly,support post 131 may be positioned at a variety of angles. For example,in some embodiments, support post 131 may be positioned at any selectedangle in a range less than 30 degrees from normal to base pan 132. Otherembodiments may have greater or lesser angular ranges, e.g. angles lessthan 20 degrees from normal, less than 10 degrees from normal, less than5 degrees from normal, etc. In various embodiments, any other suitabletype of pivot known in the art may be used, including, e.g., a ball andsocket joint, a saddle joint, a ball bearing, etc.

The angle of support post 131 may be selected to compensate for localundulations in the ground on which base pan 132 sits. For example, ifthe ground under base pan 132 had a local tilt of 20 degrees along agiven direction, the angle of support post 131 could be adjusted to 20degrees in the opposite direction, thereby compensating for the localtilt. Once the angle of support post 131 is chosen, pivot bolts 134 aand 134 b may be tightened to prevent further pivoting thereby settingthe angle in place.

Support post 131 includes an attachment mechanism (sometimes referred toas a facility), which in this example is support host bolt hole 135,which may be used to attach post 131 to support frame 120. As describedin greater detail below, support post 131 may be attached to supportframe 120 at a variety of heights, providing further flexibility tocompensate for local undulations in the ground on which base pan 132sits.

As shown in FIG. 2B, ballast 136 may be placed on support pan 132 toprovide support base 130 with mass that may assist in keeping array 100securely in place. In some embodiments, ballast 136 may comprisestandard size concrete blocks, such as, for example, blocks withdimensions of 8 inches wide×8 inches tall×16 inches long, which may beavailable at numerous home improvement and/or building supply stores.

Where the base pans 132 are designed to permit use with standard sized,commercially available blocks, the need to ship heavy ballast elementsalong with other elements of the system may be reduced (although onecould ship the ballast elements or design ballast element specificallyfor use with base pans 132). A purchaser/installer of the system couldpurchase or construct the ballast blocks locally.

For example, ballast 136 may include concrete blocks made at or near thesite where array 100 is to be positioned. Ballast 136 in someembodiments may be made from any concrete mix that is intended towithstand the elements for an appropriate period of time, such as cementintended for outdoor applications and having an intended life span of30+ years. Ballast 136 may in some embodiments be made using a PortlandType III concrete with air entrainment of about 5%. This concrete is ahigh early strength, normal weight concrete with a fully cured strengthof 5,000 psi, and is available from Precast Specialties Inc. ofAbington, Mass. Alternatively, ballast 136 may be formed from materialssuch as, for example, rocks, metal, natural or recycled rubber, orQuazite®, a polymer concrete available from Hubbell Lenoir City, Inc. ofLenoir City, Tenn., or other materials.

Although two similarly size ballast elements 136 are illustrated in FIG.2B, it is to be understood that alternate embodiments may include, forexample, left and right and/or front and back ballast elements havingdifferent configurations, multiple ballast elements positioned in anysuitable configuration, or a single ballast element. If more than twoballast elements are utilized (e.g. as shown in FIG. 8A), these ballastelements may comprise, for example, standard sized building materials,including, for example, standard sized bricks with dimensions of 3⅝inches wide×2¼inches high×8 inches long. Other embodiments featurebricks with a of nominal size of 8″×8″×16″, although other size blocksmay be used. This is a nominal size, typically the true dimensions aresmaller in each direction by ⅛-¼″. Any other dimensions may be used. Ifmore than two ballast elements are used, they may be mounted on base pan132 in a stacked or a side-by-side configuration, or both.

As shown, ballast 136 is placed on base pan 132. In some embodimentsballast 136 may be attached or affixed to base pan 132 using anysuitable means including fasteners, adhesives, hook and loop materials,etc. Base pan 132 may include a textured surface or retaining featuresto help maintain the placement of ballast 136.

Additionally, or as an alternative to ballast 136, one or more nails(e.g., 12 inch long nails) may be driven through base pan 132 into theground below to secure the support base 136. In some embodiments, basepan 132 may include one or more holes, slots, etc. (not shown) toreceive the nails and allow the nails to pass through the base pan 132into the ground.

In some embodiments, support base 130 or any component thereof may alsocontain one or more wire chases (not shown) that can be used for runningelectrical wire through the support base 130. Such wire chases mayprovide integrated wire management (e.g., allowing the electricalinterconnection of two or more solar panel modules 110) and integratedgrounding capabilities (e.g., accommodating one or more ground wires).

Referring to FIG. 3, support frame 120 includes a horizontal member 125.The front end of horizontal member 125 includes a front support frameattachment facility 126. The rear end of horizontal member 125 includesa rear support frame attachment facility 127. As shown in FIG. 1, thefront support frame attachment facility 126 of one support frame 120attaches to rear support frame attachment facility 127 of anothersupport frame 120 to form columns of support frames 120 in array 100.

Rear support frame attachment facility 127 receives the front supportframe attachment facility 126 of an adjacent support frame 120. Thisallows the horizontal members 125 of adjacent support frames to beattached, e.g., in this example, bolted together. The attachmentfacilities 126 and/or 127 may include multiple horizontally spaced boltholes, allowing the spacing between support frames (and hence modules110) to be adjusted as desired. For example, as shown, the rearattachment facility 126 includes six horizontally spaced bolt holes,while the front attachment facility 127 includes two horizontally spacedbolt holes, allowing for twelve possible spacings. Further, supportframes 120 may be a pivotably connected, allowing for adjustment of theangle at which horizontal members meet. This allows for construction ofan array 100 where the angular orientation of modules 110 may vary rowto row. Accordingly, support frames 120 allow for a great deal offlexibility in the positioning of modules 110 in array 100.

Referring again to FIG. 3, support frame 120 includes angled member 128which includes a facility to permit attachment of panels to the frame.In this example, rear mounting hole 150 is provided on the rear portionof angled member 128 and provides locations for the attachment ofattachment modules 140, described in detail below. In some embodiments,(e.g. as shown in FIG. 7) an attachment module 140 mounted to angledmember 128 through rear mounting holes 150 may be attached to a solarpanel module 110 proximate a Top edge 210 of the solar panel module 110that is vertically higher than a Bottom edge 220 of the solar panelmodule when the solar panel module 110 is mounted on some embodiments ofcertain aspects of the present embodiments. Some embodiments include afacility which allows for the adjustment of the angular orientation ofangled member 128 relative to horizontal member 125. In otherembodiments, support frame 120 is constructed as an integral unit, witha fixed orientation of horizontal member 125 and angled member 128.

The Bottom edge 220 of solar panel module 110 may be attached withanother attachment module 140 to forward mounting slots 160 on angledmember 128. Multiple forward mounting slots 160 are provided to allowflexibility in mounting panel modules 110 of various sizes. For example,FIGS. 4A and 4B show a pair of attachment modules 140, a first oneattached to mounting holes 150 and second one attached to mounting slots160 of angled member 128. The distance between the pair of modules 140may be coarsely adjusted by choosing which mounting slot 160 the secondattachment module 140 is mounted to, and more finely adjusted byslidably adjusting the position at which the module is mounted withinthe slot.

In some embodiments, edges of two solar panel modules 110 may beattached to respective sides of angled member 128 using attachmentmodules 140. As shown in FIG. 1, this allows solar panel modules 110 tobe attached to form the rows of the array 100.

As shown in FIGS. 3, 4A, and 4B, support frame 120 includes a supportpost attachment mechanism 121 which allows attachment of support frame120 to support post 131. As previously noted, this attachment mechanismallows the height of support frame 120 above support pan 132 to beadjusted. As shown, support post attachment mechanism 121 includesseveral bolt holes spaced apart vertically. Mechanism 121 receivessupport post 131 and support post 131 is bolted to mechanism 121 withbolt 122 at a desired height using support post bolt hole 135.Alternatively, in some embodiments, support base 130 and support frame120 may be constructed as an integral unit.

In some embodiments, support frame 120 (or any component thereof) mayalso contain one or more wire chases (not shown) that can be used forrunning electrical wire through the support frame 120. Such wire chasesmay provide integrated wire management and integrated groundingcapabilities.

FIG. 4 is an enlarged view of attachment module 140. Attachment module140 may in some embodiments include a threaded hole 142 and anon-threaded hole 144. In this example, attachment module 140 may beattached to support frame 120 with an appropriate attachment mechanism.In this example a bolt is used to attach attachment module 140 tosupport frame 120. In other embodiments, a metal pin or a clip may beused, or other attachment devices or mechanisms as would be apparent toone of skill in the art based on the disclosure provided herein.

Attachment module 140 may in some embodiments be made from 6061-T6aluminum which can be anodized if desired. The attachment module 140 canalso be made from other metal or some other material of sufficientstrength. Where a conductive material is selected, the attachment modulemay be used to assist in passing ground among panels. The attachmentmodule may be formed by machine cutting, but can also be extruded, lasercut, or water jet cut or formed using another suitable manufacturingmethod.

FIG. 6A illustrates one embodiment of attachment module 140 according toone aspect of the present embodiments, mounted proximate the corners ofsolar panel module 110. In this example the attachment modules 140 maybe made of a metal such as aluminum. In some embodiments, the attachmentmodules 140 may be made of a conductive material to assist in groundingof the panel modules or may include a grounding path.

Referring back to FIG. 4, attachment module 140 includes an attachmentmechanism which in this example is a threaded hole for a bolt which maybe used to attach the attachment modules 140 to a solar panel module110. The attachment module 140 may also include second, non-threadedholes for bolts 145 that may used to attach (or facilitate attaching) anattachment module 140 to support frame 120 (e.g. at rear mounting hole150 or front mounting slot 160 of angled member 128). Other attachmentmechanisms may be employed with attachment modules 140, including, forexample, screws, adhesives, clips, or solder.

Since many commercially available solar panels include a similar edge,this particular attachment module is compatible for use with solarpanels provided by multiple suppliers. This particular attachment moduleis also compatible for use with solar panel mounting systems provided bymultiple suppliers. Other designs for compatibility with multiplesuppliers may be provided based on the disclosure provided herein anddifferent attachment modules may be designed for use with differentsolar panels but made compatible for use with a common support frameconfiguration.

Other mechanisms may be employed in other embodiments to facilitateattachment of panel to support frame and those embodiments may (or maynot) provide flexibility in ability to vary the height of attachmentwith respect to the frame by allowing multiple attachment points or byallowing slidable adjustment, as would be readily designed by one ofskill in the art based on the disclosure provided herein.

In one embodiment, attachment module 140 is configured to permit it tobe attached to a plurality of different panel modules and/or panelmodule mounting systems available in the market.

FIGS. 6A-6C illustrate one example of how attachment modules 140 may beutilized to attach solar panel modules 110 to support frame 120. FIG. 6Billustrates a solar panel module with three attachment modules 140attached and one attachment module 140 unattached. As illustrated inFIGS. 6A-6C an attachment module 140 may be attached to a solar panelmodule 110 by a threaded bolt 145 passing through a threaded hole inattachment module 140 to secure attachment module 140 to an inner edgeof solar panel module 110. This provides for positioning and alignmentof solar panel module 110 relative to support frame 128. Attachmentmodules 140 may be attached through non-threaded holes or slots tosupport frame 120 by bolts passing through one of rear mounting hole 150and forward mounting slots 160 for a rear and a forward attachmentmodule 140 respectively. In this manner, solar panel modules 110 may besecured in place relative to support frame 120 and relative to oneanother in a fashion compatible with a number of commercially availablesolar panels. Other configurations may be designed to permitcompatibility with multiple panel types whether attaching at thisportion of the solar panel or designed for integration with future solarpanels, based on the disclosure provided herein.

FIG. 7 shows a solar panel module 110 with a first lateral edge 230 anda second lateral edge 240 attached to first and second support frames120A and 120B, respectively. The assembly shown in FIG. 7 can beconsidered to be a basic unit which may be repeated as shown in FIG. 1to form the array 100.

FIG. 8 shows a rear view of the array 100 of FIG. 1. Cross bracing 801provides additional support for solar panel modules 110. As shown, thecross bracing includes three bracing members which extend horizontallybetween adjacent columns of support frames 120. However, in variousembodiments, any other suitable cross bracing or mechanical supportmembers may be used. For example the embodiment in FIG. 8A included onlytwo cross bracing members extending between adjacent pairs of supportframes 120 a and 120 b.

FIG. 9 is a rear perspective view of the array 100 deployed onundulating ground. As shown, the ground 900 is generally flat and level,but includes local portions 901 having deviating heights and portion 902which has a deviating height and tilt angle.

Array 100 has been adjusted to compensate for the undulation in theground, such that the height and tilt angle of panels 110 of array 100are fixed relative to the flat and level portion of ground 900 acrossthe entire array.

Three support bases 130 a are a positioned on the flat level portion orthe ground. For these support bases 130 a, support posts 131 a areoriented normal to their respective base pans 132 a and are attached totheir respective support frame 120 a at equal heights.

Two support bases 130 b are positioned on portions 901 of ground 900which are level, but have heights which deviate from the flat and levelportion of ground 900. For these support bases 130 b, support posts 131b are also oriented normal to their respective base pans 132 b. However,they are attached to their respective support frames 120 b at heightswhich compensate for the local height deviation.

One support base 130 c is positioned on portion 902 of ground 900 whichhas both a height and a tilt angle which deviates from the flat andlevel portion of ground 900. For the support base 130 c, support post131 c is oriented at an angle from normal to its respective base pan 132b, to compensate for the tilt of portion 902. Support post 131 c is alsoattached to its respective support frame 120 b at a height whichcompensates for the local height deviation of portion 902.

Other adjustments to compensate for various configurations of undulatingground may be provided based on the disclosure provided herein. Forexample, ground 900 may be generally flat and inclined, with localundulations. In such a case, array 100 may be adjusted to compensate forthe undulation in the ground, such that the height and tilt angle ofpanels 110 of array 100 are fixed relative to the flat and inclinedportion of ground 900 across the entire array (or portions thereof).

In some cases, as shown in FIG. 9A, ground 900 may include a firstregion 910 and a second region 912 which are both generally flat withlocal undulations, but which are inclined at different slopes. As shown,because support frames 120 a and 120 b may be pivotally connected (asdiscussed in detail above), the array can accommodate the regions ofground having varying slope. Note that although two regions of varyingslope are shown, and number may be accommodated. Accordingly, array 100may be easily installed over large areas of terrain without the need forspecially constructed parts (i.e., support frames 120 in array 100 maybe all identical or substantially identical components.)

In general, the devices and techniques described herein allow groundmounted solar panel module support arrays to be designed and constructedwith ease and flexibility. Local undulations may be compensated for, andvarious suitable row and column spacings and angular orientations may beused.

Support frame 120, support base 130 can be made from metals (such asstainless steel, mild steel, aluminum, etc), UV resistant plastic,fiberglass, concrete, or other materials.

In some embodiments, one or more of base pans 132 may include a pad orsole on its underside. The sole may be made from any suitable material,e.g. a textured material which improved the grip of base pans 132 on thesupporting surface. In cases where base pans 132 are not placed on theground but, e.g. on a roof surface, material that can be considered an“inert pad” by the roofing industry may be used. In some embodiments,the sole may be made from recycled, non-vulcanized crumb rubber, such asthat available from Unity Creations Ltd. of Hicksville, N.Y. In otherembodiments the sole may be made from natural rubber, EPDM (EthylenePropylene Diene Monomer—a rubber roofing material), or another roofingmaterial that may protect the roof or other surface upon which array 100may be mounted from damage. The sole may be attached to the underside ofbase pan 132 using any suitable attachment, e.g. adhesive, fasteners,etc.

FIGS. 10A-10D show alternative embodiments of attachment module 140.Referring to FIG. 10A, attachment module 140 a includes upper member 301and lower member 302. An inner edge of panel 110 (not shown) can beattached between the upper and lower members. The inner edge may includea hole (e.g. a pre-formed hole provided by the panel manufacturer).Threaded bolt 303 can pass through a threaded bolt hole in the lowermember, through the hole in the inner edge, and into a threaded bolthole in upper member 301. Holes 304 in lower member 302 may be used toattach the attachment module 140 a to support frame 120, e.g. using anattachment bolt.

Referring to FIG. 10B, attachment module 140 b includes a c-shapedmember 305 and a flat angled member 306. An inner edge of panel 110 (notshown) can be attached between the members 305 and 306. Threaded bolt307 may pass through a threaded bolt hole in the c-shaped member toclamp the inner edge between members 305 and 306. Slot 308 in flatangled member 306 may be used to attach the attachment module 140 a tosupport frame 120, e.g. using an attachment bolt.

Referring to FIG. 10C, attachment module 140 c may be used forattachment to a panel module 110 which lacks an inner edge along itslateral side, but includes an inner edge along its Top or Bottom side.Attachment module 140 a allows for the panels of this type to be mountedto support frames 120 of the type shown in FIG. 1 without additionalmodification.

Attachment module 104 c includes a c-shaped member 309 and an extensionmember 310. A Top or Bottom inner edge of panel 110 (not shown) can beattached between the c-shaped member 309, and portion 311 of attachmentmember 310. Threaded bolt 307 may pass through a threaded bolt hole inthe c-shaped member to clamp the inner edge between members 305 and 306.

Attachment module 140 c may be attached to panel module 110 proximal toa corner of the panel, such that portion 312 of extension member 310extends out past the lateral side of the panel for mounting to supportframe 120. Hole 313 in attachment member 310 may be used to attach theattachment module 140 c to support frame 120, e.g. using an attachmentbolt. Note that although exemplary dimensions are provided in thefigure, any suitable dimensions may be used.

Referring to FIG. 10D, attachment module 140 d includes upper member 301and lower member 304. The members are connected by at pivot 316, therebyforming “jaws” that can open and close. An inner edge of panel 110 (notshown) can be attached between the jaws formed by members 314 and 315.The pivoting of the jaws allows attachment module 140 d to attach toinner edges having a variety of shapes and sizes, including irregularshapes. Thus, attachment module 140 d may be compatible with multipletypes of panels, and/or with panels of a single type which (e.g. due tomanufacturing errors) have inner edges of varying shape or size.

In cases where the inner edge includes a hole (e.g. a pre-formed holeprovided by the panel manufacturer), Threaded bolt 317 can pass througha threaded bolt hole in the lower member, through the hole in the inneredge, and into a threaded bolt hole in upper member 301. In cases wherethe inner edge does not include a hole, threaded bolt 317 can be used toclamp the edge in place. Holes 304 in lower member 302 may be used toattach the attachment module 140 a to support frame 120, e.g. using anattachment bolt.

Referring to FIGS. 12A and 12B attachment module 140 e includes twofacilities 601 a and 601 b (e.g., flanges or tabs including one or morebolt or screw holes) which can each attach to a support frame (e.g.,each facility may be attached to adjacent support frames in an array).Elongated member 602 extends between facilities 601 a and 601 b, andincludes surfaces 604 adapted to be placed in intimate contact withflange 606 on solar panel module 110. One or more threaded or unthreadedscrew or bolt holes may be used to secure attachment module 140 e toflange 606. Attachment module 140 e may include one or more apertures608 (or other slots, openings, etc.) to allow access to one or morefeatures on module 110 such as a ground lug, wire connector, etc (seeFIG. 12B, inset).

Note that when attachment module 140 e is used to mount solar panelmodule 110 on one or more support frames 120, the elongated member 602operates to spread the force on the module 110 over a relatively largearea (e.g. as compared to the mounting configuration shown in FIGS.6A-6C, where attachment modules 140 couple to solar panel module 110 atfour discrete positions), thereby reducing potentially disadvantageouseffect due to, e.g., bowing or bending of solar panel module 110.

Referring to FIG. 11, there is illustrated a flowchart 500 of a methodof forming a solar module array of the type described above.

In act 510, support bases 130 are positioned on the ground (or anothersurface). In some embodiments, ballast may be added to secure the basesto the ground. In some embodiments, one or more nails (e.g., 12″ nails)or similar devices may be embedding in the ground through support base130 (in addition to or as an alternative to ballast) to secure thesupport base to the ground. In some embodiments support base 130 mayinclude apertures, openings, slots, etc. to accommodate the nails.

In act 520, the angles of support posts 131 relative to support pans 132are adjusted to compensate for local undulations in the ground, and setto a desired angle. For example, as described above, pivot 133 may beused to adjust the angle, and pivot bolts 134 a and 134 b may betightened to prevent further pivoting thereby setting the angle inplace.

In act 530, support frames 120 are attached to support posts 131 atheights selected to compensate for local undulations in the ground. Forexample, as described above, support post attachment mechanism 121includes several bolt holes spaced apart vertically. Mechanism 121receives support post 131 and support post 131 is bolted to mechanism121 with bolt 122 at a desired height using support post bolt hole 135.

In act 540, support frames 120 are attached to each other to formcolumns of the array. As described in detail above, in some embodiments,the support frames may be attached in such a way that the spacing of thesupport frames 120 may be varied over the array (e.g., to provide variedrow to row spacings). Further, as described in detail above, in someembodiments the some or all of the attachment points for support framesmay be pivotable, to allow for adjustment of the angle orientation ofthe attached support frames (e.g., to accommodate regions of varyingslope in the surface on which the array is located). In someembodiments, the cross bracing is attached between support frames inadjacent columns in the array (e.g. as shown in FIGS. 8 and 8A). In someembodiments, cross bracing 801 may be attached loosely, and tightenedafter the attachment of the solar panel modules 110 to the supportframes 120, e.g., as described in act 560 described below.

In act 550, attachment modules 140 are attached to solar panel modules110.

In act 560, solar panel modules 110 are attached to support frames 120using the attachment modules 140. Note that, in some embodiments, solarpanel modules 110 may be attached to the support frames 120 only afterall or substantially all of the support frames 120 are in place andattached. As described above, in some embodiments, cross bracing 801 maybe tightened after the attachment of the solar panel modules 110.

It is to be appreciated that acts 510-560 of flowchart 500 may in someembodiments be performed in alternate orders. It is also to beappreciated that not all acts need be performed in all embodiments, andthat in some embodiments additional or alternate acts may be performed.Some embodiments of the installation method described above may includefurther acts, including: e.g., running wires through one or more wirechases in the array to connect solar panel modules 110, or to providegrounding. Some embodiments may include the act of forming ballast at ornear the site on which array is located (e.g., using cement, concrete,etc.).

Solar panel module installation systems of the type described hereinprovide a number of features and advantages. In some embodiments, theinstallation may be completed without the use of heavy tools andmachinery. For example, as described above, in some embodiments, none orsubstantially none, of the components of the system are embedded in theground. Accordingly, the need for excavation tools (e.g., post holediggers, etc.) is avoided.

In some embodiments, the entire system may be composed of only a fewdifferent component types. For example, in some embodiments, the systemincludes only sets of support bases 130, support frames 120, attachmentmodules 140 and, optionally, cross bracing 801 and various hardware(e.g., limited to screws, nuts, and bolts). In some embodiments, anentire array may be constructed using only these sets of identicalcomponents. However, as described in detail above, the installationremains highly customizable, with the ability to adjust for surfaceundulations, variations in surface slope, variation in array elementspacing, etc. Note also that the use of only a few components simplifiesmanufacturing and shipping.

In various embodiments, the various devices, systems, components,features, techniques, etc. described herein may be used in any suitablecombination.

Having thus described several aspects of at least one embodiment of thistechnology, it is to be appreciated various alterations, modifications,and improvements will readily occur to those skilled in the art. Suchalterations, modifications, and improvements are intended to be part ofthis disclosure, and are intended to be within the spirit and scope ofthe embodiments. Accordingly, the foregoing description and drawings areby way of example only.

What is claimed is:
 1. A solar panel module mounting system comprising:a support base; a support post; a pivot coupling the support post to thesupport base; and a support frame coupled to the support post to supporta solar panel module above a surface, the support frame comprising: afirst elongated member coupled at a right angle to the support post andextending from a front end to a rear end of the support frame; and afirst facility for adjusting a height of the first elongated memberrelative to the support base to a selected one of a plurality ofheights.
 2. The solar panel module mounting system of claim 1, furthercomprising a second elongated member extending at an angle to the firstelongated member from the front end to the rear end of the supportframe.
 3. The solar panel module mounting system of claim 2, furthercomprising a second facility for adjusting the angle of the secondelongated member to the first elongated member to a selected one of aplurality of angles.
 4. The solar panel module mounting system of claim2, wherein an angular orientation of the first elongated member relativeto the second elongated member is adjusted to compensate for a variationin a slope of the surface underlying the solar panel module mountingsystem.
 5. The solar panel module mounting system of claim 1, whereinthe pivot is configured to allow the support post to pivot about atleast two transverse axes.
 6. The solar panel module mounting system ofclaim 5, wherein the pivot is configured to allow the support post topivot at a range angles from about 0 to at least about 5 degrees fromperpendicular to the support base.
 7. The solar panel module mountingsystem of claim 5, wherein the pivot is configured to allow the supportpost to pivot at a range angles from 0 to at least about 10 degrees fromperpendicular to the support base.
 8. The solar panel module mountingsystem of claim 5, wherein the pivot is configured to allow the supportpost to pivot at a range angles from 0 to at least about 30 degrees fromnormal to the support base.
 9. The solar panel module mounting system ofclaim 5, wherein the support base comprises a base pan for receiving andbearing the weight of a ballast, the base pan configured and arranged toreceive the ballast in a position such that the ballast does notinterfere with a pivoting motion of the support post.
 10. The solarpanel module mounting system of claim 1, wherein the front end of thefirst elongated member comprises a third facility for attachment to anadjacent solar panel module mounting system component.
 11. The solarpanel module mounting system of claim 10, wherein the third facility forattachment of the first elongated member to an adjacent second solarpanel module mounting system component is configured to allow adjustmentof at least one of an attachment angle and a spacing between thecomponent and the adjacent second solar panel module mounting systemcomponent.
 12. The solar panel module mounting system of claim 1,wherein, when deployed on a surface, substantially no portion of thesolar panel module mounting system extends through the surface.
 13. Thesolar panel module mounting system of claim 1, further comprising one ormore nails extending through the solar panel module mounting system andthe surface to secure the solar panel module mounting system to thesurface.
 14. A method of installing a solar panel array, the methodcomprising: obtaining a first support mechanism comprising: a supportpost pivotably attached to a support base and multiple attachment pointson the support post configured for attaching a solar panel at differentheights above the support base; a support frame coupled to the supportpost, the support frame comprising a first elongated member coupled tothe support post and extending from a front end to a rear end along adirection substantially perpendicular to the support post, and a firstfacility for adjusting the height of the first elongated member relativeto the support base to a selected one of a plurality of heights;selecting an angular orientation of the support post with respect to thesupport base; setting the selected angular orientation of the supportpost; selecting a height of the first elongated member relative to thesupport base; setting the height of the first elongated member relativeto the support base to the selected height; selecting one of themultiple attachment points at a selected height on the first supportmechanism for attaching a first solar panel; and attaching the firstsolar panel to the first support mechanism at the selected height usingthe selected one of the multiple attachment points.
 15. The method ofclaim 14, wherein the first support mechanism further comprises a secondelongated member extending at an angle to the first elongated memberbetween a front end of the second elongated member coupled to the frontend of the first elongated member and a rear end of the second elongatedmember, the second elongated member including a second facility adaptedto receive an attachment module to couple the first solar panel to thesupport frame.
 16. The method of claim 15, further comprising: selectinga mounting angle of the first solar panel; setting the angle of thesecond elongated member relative to the first elongated member tocorrespond to the mounting angle of the first solar panel.
 17. Themethod of claim 14, further comprising selecting the angular orientationof the support post to compensate for a local undulation in a surface onwhich the first support mechanism is located.
 18. The method of claim17, further comprising selecting the height on the first supportmechanism for attaching the to compensate for the local undulation inthe surface on which the first support mechanism is located.
 19. Themethod of claim 14, wherein attaching the first panel to the firstsupport mechanism comprises: coupling an attachment module to the firstsolar panel; and coupling the attachment module to the first supportmechanism.
 20. The method of claim 14, further comprising: attaching asecond solar panel to the first support mechanism by coupling anattachment module to the second solar panel; and coupling the attachmentmodule to the first support mechanism.